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Currently, in many countries, aviation safety regulations allow piston engines exploitation above Time Between Overhaul (TBO) recommended by manufacturers. Upon fulfillment of certain requirements, which are already included in the manufacturers’ documentation, TBO extension is granted. National Aviation Authority has approved exploitation of piston engines to something like quasi on-condition maintenance, which has no technical proof behind. This leads to the conclusion that the current, simple way of the engine’s life extension is not the best solution for maintaining flight safety. Aircraft piston engines TBO extension requires changes in the current exploitation system.

The paper provides methodology for aircraft piston engines on-condition exploitation based on engine flight parameters (from cruise and takeoff) and engine oil particles analysis. The paper describes a method of diagnostic limits for certain engine parameters and elements in the oil assignation assuming that they come under rules of normal distribution.

It has been found that piston engines installed on maximum takeoff mass <5,700 kg class aircraft are the second biggest contributor as a source of aviation events, thereby having a significant impact on aviation safety. Engine flight parameters and elements content in the oil meet Gaussian rules.

Introduction of the engine on-condition exploitation into operation practices reduces the operator’s engine direct maintenance cost and increases technical knowledge of the employees and has a positive impact on flight safety.

It is the first scientific description in Poland, which proposes an empirically proved methodology of the aviation piston engines on-condition exploitation.

Europe has adopted Flight Path 2050 (FP 2050) challenge with an objective of 90 per cent of the travelers being able to reach door-to-door European destinations within 4 hours by 2050. The aim can be achieved by reliable, well-organized small aircraft transport (SAT). Analysis of the currently operating small aircraft operational reliability data will support the development of future aircraft designs as well as reliability and safety requirements necessary for commercial operations.

The paper provides results of a statistical analysis of small aircraft current operations based on the reported events contained in the Database named European Coordination Centre for Aviation Incident Reporting Systems database. It presents identified safety indicators and focuses particularly on those related to the aviation technology.

It has been found that certain airframe and powerplant systems have the biggest influence on flight safety.

Multidisciplinary analysis of the operational and aircraft components reliability data will help in a proper preparation of the SAT supporting facilities, a design process of new aircraft and improvements of the existing airframe and powerplant systems.

Presented results are valuable for further developments of the statistical tools facilitating new product introduction.